Method and mechanism for attaching a locking mechanism to a pick-up truck tailgate

ABSTRACT

A method of mounting a lock to a pick-up truck tailgate latching mechanism including the steps of locating targets for holes to be formed in a plastic bezel, the bezel carrying a handle for the tailgate, forming the holes in the plastic bezel, and securing the locking mechanism to the bezel via the formed holes.

RELATED APPLICATION(S)

This application is a continuation of U.S. application Ser. No.11/978,994, filed on Oct. 30, 2007, now U.S. Pat. No. 7,971,460, whichclaims the benefit of U.S. Provisional Application No. 60/855,300 filedOct. 30, 2006. The entire teachings of the above application(s) areincorporated herein by reference.

BACKGROUND OF THE INVENTION

A pickup truck typically has a cargo space secured by a tailgate.Pulling up on the tailgate handle releases a latching mechanism so thatthe tailgate may be swung down around its hinges to a horizontalposition to provide access to the cargo area for loading and unloading.Generally, the hinges are constructed to permit lifting the tailgate offits hinges when it is in the horizontal position and removing it fromthe truck.

The need to lock the tailgate is twofold. First, particularly when acamper top or a tonneau cover is mounted on the truck, it is desirableto be able to lock the tailgate to protect the gear stowed inside.Secondly, the tailgate itself is a desirable object for theft.

A tailgate is generally constructed as a box section with the innerpanel and the outer panel spaced apart by several inches. The handle andthe latching mechanism are mounted between the two panels. To installthe latching mechanism, truck manufacturers have taken two differentapproaches. One approach is to insert the mechanism from the inside, byproviding a removable access door on the inside panel. The other, lessexpensive approach is to insert the mechanism from the outside through ahandle aperture in the outside panel. In that instance, the handleaperture must be made big enough to accommodate the latching mechanism.To improve the appearance of the tailgate exterior, a snap-in plasticbezel may be mounted to the tailgate outer panel filling the voidbetween the handle and the edges of an aperture. Some bezels have anaperture roughly equivalent in size to the handle of the tailgatelatching mechanism such that if the tailgate were disassembled, thehandle could be passed through the aperture. The aperture, in thisconfiguration, is generally hidden from casual view by the handle whenthe tailgate is properly assembled. In an alternative configuration, thebezel may only have small apertures that accommodate a portion of thehandle, such as arms that attach the handle to actuating mechanisms forthe tailgate on the interior of the tailgate.

One anti-theft device comprises a replacement bezel supporting a lockwith a locking arm that prevents actuation of the tailgate handle andwith a locking bolt that prevents removal of the bezel when the deviceis in the locked position. While this device affords a convenient andsecure anti-theft solution, it is relatively expensive to manufacture.The replacement bezel has an intricate shape with retaining clips thathas to be molded by precision injection molding tools. A truckmanufacturer can amortize the cost of these tools over the entire numberof trucks that are manufactured. However, an after-market manufacturerof the replacement bezel has to amortize the same tooling cost over amuch smaller number of units sold, which adds significantly to the costof those units. In addition, the cost of the prior anti-theft device israised further by the need for both a locking arm and a locking bolt.

SUMMARY OF THE INVENTION

The present invention comprises a locking mechanism mounted to theplastic bezel of a tailgate that requires only minor modification to thebezel when the bezel does not provide ready access to the interiorcomponents of the tailgate.

In one embodiment of the invention comprises a method of mounting a lockto a tailgate comprising the steps of locating targets for holes to bedrilled in the plastic bezel surrounding a tailgate handle, forming oneor more holes at the targets, and securing a locking mechanism at anexterior portion of the bezel via the one or more holes.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing will be apparent from the following more particulardescription of example embodiments of the invention, as illustrated inthe accompanying drawings in which like reference characters refer tothe same parts throughout the different views. The drawings are notnecessarily to scale, emphasis instead being placed upon illustratingembodiments of the present invention.

FIG. 1A shows a typical pick-up truck bed and a tailgate with twolatches;

FIG. 1B shows the tailgate of FIG. 1A with the tailgate swung down to anopen position;

FIG. 1C shows the tailgate of FIG. 1A with the tailgate swung to theside in an open position;

FIG. 2A shows a detail view of the exterior portion of a handleassembly;

FIG. 2B shows a detail view of the interior portion of a handleassembly;

FIG. 3A shows a method of using a template to locate a hole to bedrilled in a first embodiment of a handle assembly;

FIG. 3B shows an exploded view of the handle assembly of FIG. 3A and alocking mechanism;

FIG. 3C shows the handle assembly and locking mechanism of FIG. 3B froman exterior perspective;

FIG. 3D shows a cross sectional view of the handle assembly and lockingmechanism of FIG. 3B;

FIG. 4A shows a detail view of the interior portion of a secondembodiment of a handle assembly;

FIG. 4B shows a method of using portions of the handle assembly tolocate a hole to be drilled in the handle assembly of FIG. 4A;

FIG. 4C shows an exploded view of the handle assembly of FIG. 4A and alocking mechanism;

FIG. 4D shows a cross sectional view of the handle assembly and lockingmechanism of FIG. 4C;

FIG. 5A shows an exploded view of a handle assembly and a lockingmechanism according to a third embodiment;

FIG. 5B shows a cross sectional view of the handle assembly and lockingmechanism of FIG. 5A;

FIG. 6 shows an exploded view of a handle assembly and a lockingmechanism according to a fourth embodiment;

FIG. 7 shows an interior view of a tailgate latching mechanism and aninterfering locking cam mechanism; and

FIG. 8 shows an exploded view of a locking mechanism.

DETAILED DESCRIPTION OF THE INVENTION

A description of example embodiments of the invention follows.

In U.S. Pat. No. 6,427,502 (“the '502 patent”), I disclosed a lockingmechanism that includes a mounting bracket that passes through a largeaperture in a bezel of a tailgate. The locking mechanism disclosed inthat patent is generally seated immediately beneath the tailgate handlein a recess. The locking mechanism includes a cam that moves between afirst position and a second position. In the first position, the caminterferes with the path of movement of the tailgate handle, preventingthe handle from being pulled, effectively locking the tailgate. In thesecond position, the cam does not interfere with the path of movement ofthe tailgate handle, allowing the handle to be pulled.

The locking mechanism disclosed in the '502 patent does not address twoissues. First, some tailgate bezels do not include the large aperturethat would allow bracket mounting as taught in the '502 patent. Second,some tailgates are now constructed to allow swinging in two directions:swinging down on a horizontal axis or swinging to the side on a verticalaxis. These bi-directional tailgates often have two separate handles,each handle controlling the latching mechanism for one of the two typesof movement. A single locking mechanism of the type disclosed in the'502 patent cannot effectively lock such a tailgate.

The locking mechanism disclosed herein may be mounted to a bezel withoutan adequately sized aperture for a bracket. Furthermore, this lockingmechanism may be mounted to the bezel to allow the locking mechanism tocreate a moveable interference with a portion of the tailgate latchingmechanism utilized in all directions of movement of the tailgate.

FIG. 1A shows a typically configured pick-up truck bed 100 with a cargoarea 102. The cargo area 102 is boxed in by a front wall 126, two sidewalls 118, 120, and a tailgate 104. FIG. 1A shows two bezels 106, 110,each bezel carrying a handle 108, 112 mounted to tailgate 104. FIG. 1Bshows a typical mounting and movement of a tailgate 104, in which thetailgate is rotated in the direction of arrow 114 by hinge 122. Handle108, when pulled, releases latches (not shown), freeing the tailgate toswing around hinge 122 in the direction of arrow 114. FIG. 1C shows asecond mounting and movement of a tailgate 104, in which the tailgate isrotated in the direction of arrow 116 by hinge 124. Handle 112, whenpulled, releases latches (not shown), freeing the tailgate to swingaround hinge 124 in the direction of arrow 116. A pick-up truck may beequipped with one or both of the latch/hinge configurations shown above.The exact placement of the handles 108, 112 are not important.

FIG. 2A shows an exemplary handle assembly 200 that would be mounted inthe tailgate 104 of a pick-up truck. The handle assembly 200, as shownin FIG. 2A includes an exterior portion of a bezel 204, typically madeof plastic, surrounding a handle 202. The handle 202 is pivotallymounted to arm portions 214 of the handle assembly 200 with pins 210.The handle 202 also has arms 208 that interact with the latchingmechanism (not shown) inside the tailgate 104. The exterior portion ofthe plastic bezel 204 includes a recess 206 providing access to grip thehandle 202.

FIG. 2B shows an opposite view of the exemplary handle assembly 200 ofFIG. 2A. The view in FIG. 2B shows an interior portion of the bezel 212and clearly shows the arm portions 214 of the handle assembly 200. FIG.2B also shows bolts 216 screwed into bolt receptacles (not visible)located on the interior portion of the bezel 212. The bolt receptaclesare typically molded in the handle assembly 200. When the handleassembly 200 is installed in a tailgate 104, bolts 216 would also passthrough an interior mounting (not shown) in the tailgate 104 to rigidlyattach the handle assembly 200 to the tailgate 104.

FIGS. 3A-3D show one method of attaching a locking mechanism 312 (shownin FIGS. 3B-3D) to a handle assembly 200. FIG. 3A shows the interiorportion of bezel 212. Template 304 is attached to handle assembly 200 bybolts 216. Template 304 is attached by temporarily removing bolts 216 sotemplate 304 can be moved into place such that holes (not visible) intemplate 304 align with holes (not visible) located on the interiorportion of the bezel 212. Bolts 216 are then replaced, rigidly holdingtemplate 304 in place relative to the interior portion of the bezel 212.Template 304 also could be rigidly held by pins, dowels, rivets, orscrews instead of using bolts 216. Note that when bolts 216 are removedfrom handle assembly 200, the handle assembly 200 may be easily removedfrom tailgate 104, which may make the method disclosed herein easier toperform. After template 304 is installed on the interior portion of thebezel 212, a drill 300 and drill bit 302 are used to drill a hole (notvisible) in the handle assembly 200 from the interior portion of thebezel 212 to the exterior portion of the bezel 204. The drill bit 302 ispositioned and guided during the drilling process by hole 306 located intemplate 304.

As illustrated in FIG. 3B, after hole 308 is drilled in the handleassembly 200, lock assembly 312 is mounted to the exterior portion ofthe bezel 204, in recess 206 in this example. The lock assembly 312 isheld in place by bolt 310, which passes through hole 308 to interfacewith bolt receptacle 318. Alternatively, the lock assembly 312 can beheld in place by a rivet passing through hole 308 or by a threadedportion of the locking mechanism (not shown) that passes through hole308 and tightening a nut onto the threads extending to the interiorportion of the plastic bezel. Note that FIG. 3B shows template 304 beingremoved prior to the installation of lock assembly 312 and bolt 310.Alternatively, template 304 could be left in place such that bolt 310passes through template guide hole 306 and hole 308 in handle assembly200.

Lock assembly 312, in addition to bolt receptacle 318, also has a lockcylinder 314 and a cam 316. The lock cylinder 314, in this example, hasa square end portion, enabling the cam 316 to be properly rotationallypositioned with respect to lock cylinder 314.

FIG. 3C shows the handle assembly 200 and a view of the exterior portionof bezel 204 with lock assembly 312 installed. Lock assembly 312, inthis embodiment, is nestled within recess 206. A key interface 320 ispresent on an exterior surface of lock assembly 312 for a user to inserta key (not shown) and turn the lock to engage cam 316 in either a lockedposition or an unlocked position. Lock assembly 312, in this example,fills a portion of recess 206, but still leaves room for access tohandle 202.

FIG. 3D shows the handle assembly 200 with installed lock assembly 312in cross-section. For clarity, lock cylinder 314 is removed in FIG. 3Dand replaced with a representation of its axis of rotation 322. Cam 316is shown in the “locked” position, wherein a portion of cam 316interferes with the path of movement 324 of handle 202. If someone triesto open the tailgate 104 by pulling handle 202, cam 316 will preventhandle 202 from moving far enough for arm 208 to actuate the tailgatelatching mechanism (not shown).

FIGS. 4A-4D show an alternative method of mounting a lock mechanism 312to a handle assembly 400. FIG. 4A shows the interior portion of thebezel 402 of the handle assembly 400. The interior portion of the bezel402 includes a raised cylindrical boss 404, which surrounds a hole 406extending through the boss 404. The hole 406, if extended to theexterior portion of the bezel 204, would also be present in the recessarea 206. However, when the bezel is molded, the hole 406, at theexterior end, is covered with plastic. When a user wishes to add a lockmechanism 312 to the handle assembly, a drill 300 and drill bit 302, asshown in FIG. 4B, are used to create hole 406. Drill bit 302 is insertedinto hole 406. Hole 406 guides drill bit 302 to properly drill out thebezel material in recess 206, making the hole continuous from theinterior portion of the bezel 402 to the exterior portion of the bezel202.

After the hole is formed, lock assembly 312 is mounted to the exteriorportion of the bezel 204, in recess 206. Bolt 408 passes through hole406 and interfaces with bolt receptacle 318 in the lock assembly as isshown in FIG. 4C. FIG. 4D shows the handle assembly 400 with installedlock assembly 312 in cross-section. For clarity, lock cylinder 314 isremoved in FIG. 3D and replaced with a representation of its axis ofrotation 322. Cam 316 is shown in the “locked” position, wherein aportion of cam 316 interferes with the path of movement 324 of handle202. If someone tries to open the tailgate 104 by pulling handle 202,cam 316 will prevent handle 202 from moving far enough for arm 208 toactuate the tailgate latching mechanism (not shown).

A further embodiment is shown in FIGS. 5A and 5B. FIG. 5A shows theinterior portion of the bezel 212 of handle assembly 200 of FIG. 3B,except two holes 308, 502 have been drilled in the handle assembly 200.If a template is used like the template 304 used in the embodiment ofFIGS. 3A-3D, then the template here (not shown) would have two holes formaking holes 308 and 502. Here, as in FIG. 3B, bolt 310 passes throughhole 308 and into bolt receptacle 318 of the lock mechanism 312.However, in this embodiment, lock cylinder 314 is longer and, wheninstalled into the handle assembly 200, lock cylinder 314 extendsthrough hole 502 such that cam 316 is located beyond the interiorportion of the bezel 212. FIG. 5B shows this embodiment incross-section. Lock cylinder 314 is not shown, but its axis of rotation504 is shown extending through the bezel at recess 206. Cam 316 is shownbeyond the interior portion of the bezel 212. In this position, cam 316does not interfere with the path of movement 324 of handle 202. However,cam 316 may now interfere with other portions of the tailgate latchingmechanism (not shown) that ultimately attach to arm 208 of handle 202.This arrangement, wherein the cam 316 interferes with internal portionsof the tailgate 104 latching mechanism (not shown) may be preferable fortailgates 104 such as that illustrated in FIGS. 1A-1C, in which thereare multiple handles 108, 112, each handle 108, 112 actuating a portionof the latching mechanism (not shown) to cause the tailgate 104 toeither swing down, as in FIG. 1B, or swing to the side, as in FIG. 1C. Aperson having ordinary skill in the art would understand that cam 316could be shaped and positioned to interfere with the movement oflatching mechanism (not shown) for both handles 108, 112. A personhaving ordinary skill in the art would also understand that cam 316 maybe installed on lock cylinder 314 after lock cylinder 314 is passedthrough hole 502.

FIG. 6 shows a further embodiment in which the lock assembly 600 ismounted on an exterior portion of the bezel 204 away from the recess 206for the handle 202. In this case, the lock shaft 314 and cam 316 have topenetrate the handle assembly 200 to reach past the interior portion ofthe bezel 212 to interact with the latching mechanism (not shown). FIG.6 shows holes 602 and 604 drilled in the handle assembly 200 to receivebolt 310 and lock shaft 314, respectively. Like the embodiments in FIGS.5A-5B, when the lock assembly 600 is installed on the handle assembly200, the cam 316 will be positioned to interfere with portions of thetailgate latching mechanism (not shown). A person having ordinary skillin the art would understand that cam 316 could be shaped and positionedto interfere with the movement of latching mechanism (not shown) forboth handles 108, 112. A person having ordinary skill in the art wouldalso understand that cam 316 may be installed on lock cylinder 314 afterlock cylinder 314 is passed through hole 604.

FIG. 7 shows a locking mechanism for a dual mode hinge tailgate such asdescribed in U.S. Pat. No. 6,938,941. Such tailgates can be openedeither side ways or up and down. Two separate handles are provided foreach mode of operation. A synchronizing linkage mechanism assures thatthe tailgate cannot be opened both ways simultaneously.

The layout of my invention is shown in FIG. 7 in a plan view. Thelinkage 1 that opens the tailgate horizontally is actuated by a rod 2that connects to the tailgate handle. The linkage 4 that opens thetailgate sideways is actuated by a cable pull that connects to a secondhandle (not shown). According to my invention a Bolt 5 is mounted sothat it pivots on rivet 6. Bolt 5 has a tooth 7 and another tooth 8which engage linkage 1 and linkage 4 respectively. When Bolt 5 is turnedto the right it blocks linkages 1 and 4 from moving, thus locking thetailgate. A Spring 9 is arranged to provide an over center force thatbiases the Bolt 5 either to the right in the locked position, or whenthe Bolt 5 is turned a few degrees to the left, it biases the Bolt 5 tothe unlocked position.

Bolt 5 carries two lugs 11 and 10. Lug 11 engages Actuator Bolt 17 witha slot 18 that provides some lost motion between the two. Electromechanical Actuator 19 can pull the Actuator Bolt 17 to lock the Bolt 5,or can push it to unlock the Bolt 5, depending on the polarity of theapplied voltage. Spring 20 returns the Actuator Bolt 17 to the neutralposition when no voltage is applied to the Actuator 19.

Lug 1 engages Connecting Rod 12 with a slot 13 that also provides somelost motion between the two. The Crank 15 can pull the Connecting Rod 12to also lock Bolt 5, or can push it to also unlock Bolt 5. Crank 15attaches to the Lock Shaft (shown in detail in FIG. 8) and can be turnedmanually 45 degrees in both directions by the Key of the Lock.

FIG. 8 shows the mechanism by which the Shaft 43 is spring loaded toreturn to the neutral position by the Spring 47 after the key isreleased. Additionally, Detent Spring 45 and Ball 44 bias the Shaft inthe neutral position.

One feature of my invention is that the Tailgate can be locked andunlocked both electrically or manually by virtue of the lost motionafforded by the Slots 13 and 18 and the fact that both the Actuator andthe Lock are spring loaded to return to the neutral position. Since boththe Actuator Bolt 17 and the Connecting Rod 12 are spring loaded in theneutral position, either linkage can be actuated to lock or unlock theBolt 5. The advantage of this feature is that since both modes functionindependently, the tailgate can be operated manually in the case ofbattery failure, or conversely, electrically if the key is misplaced.

The teachings of all patents, published applications and referencescited herein are incorporated by reference in their entirety.

While this invention has been particularly shown and described withreferences to example embodiments thereof, it will be understood bythose skilled in the art that various changes in form and details may bemade therein without departing from the scope of the inventionencompassed by the appended claims.

What is claimed is:
 1. A locking mechanism for a pick-up truck tailgatelatching mechanism comprising: a lock cylinder, the cylinder including ashaft rotated by a key; a cam attached to the shaft of the lockcylinder, the cam moveable between a first position and a secondposition; at least one fastener; and a housing carrying the lockcylinder and cam, the housing further comprising an exterior portion andan interior portion and a fastener receptacle on the interior portion ofthe housing, the housing being mountable to an exterior portion of aplastic bezel of the pick-up truck, the plastic bezel carrying a handleactuating a tailgate latching mechanism and comprising a fastener holeand a lock cylinder hole, the housing being secured to the plastic bezelby coupling the at least one fastener through the plastic bezel to thefastener receptacle on the interior portion of the housing via thefastener hole in the plastic bezel so as to secure the housing to theplastic bezel via the fastener receptacle, the lock cylinder beinginsertable through the lock cylinder hole in the plastic bezel such thatthe cam attached to the shaft of the lock cylinder protrudes through thelock cylinder hole to an interior portion of the plastic bezel of thepick-up truck such that the cam interferes with a tailgate latchingmechanism in the first position and does not interfere with the tailgatelatching mechanism in the second position.
 2. The locking mechanism ofclaim 1 wherein the housing is positioned on the plastic bezel such thatthe cam interferes with the movement of the handle for actuating thetailgate latching mechanism in the first position and does not interferewith the movement of the handle in the second position.
 3. The lockingmechanism of claim 1 further comprising a plate carrying one or moreholes matching the one or more holes in the plastic bezel; and whereinthe at least one fastener couples to the locking mechanism via the oneor more holes in the plastic bezel and the one or more holes in theplate.
 4. The locking mechanism of claim 1 wherein the plate iscomprised of metal.
 5. A locking mechanism for a pick-up truck tailgatelatching mechanism, the pick-up truck tailgate comprising a bezel, thebezel having an interior portion and an exterior portion and comprisinga handle capable of actuating a tailgate latching mechanism, the bezelfurther comprising a fastener hole and a lock cylinder hole; the lockingmechanism comprising: a lock cylinder, the cylinder including a shaftrotated by a key; a bolt; a cam attachable to the shaft of the lockcylinder, the cam being moveable between a first position and a secondposition; and a housing comprising an exterior portion accepting thelock cylinder and an interior portion, the interior portion furthercomprising a bolt receptacle, the bolt receptacle designed to interfacewith the fastener hole in the bezel such that a bolt inserted from theinterior portion of the bezel through the bezel and into the boltreceptacle can be tightened to secure the housing to the exteriorportion of the bezel and such that the lock cylinder can be insertedthrough the lock cylinder aperture in the bezel such that the camattached to the shaft of the lock cylinder protrudes through the lockcylinder hole to an interior portion of the plastic bezel of the pick-uptruck; wherein the cam is capable of actuating the tailgate lockingmechanism.